Apparatus for Containment of Molten Aluminum Using Non-Wetting Materials

Abstract

An apparatus for containment of a molten substance using non-wetting materials comprising a crucible, and a layer of a non-wetting material deposited onto the crucible, wherein said layer of non-wetting material is deposited near the rim of the crucible and wherein the non-wetting material is deposited onto the crucible by one selected from the group consisting of RF magnetron sputtering, chemical vapor deposition, thermal spray, thermal evaporation, dip coating of precursors followed by thermal treatment, and spray coating of precursors followed by thermal treatment.

What we claim is: 
     
         1 . An apparatus for containment of a molten substance using non-wetting materials comprising:
 a crucible;   a layer of a non-wetting material deposited onto the crucible;   wherein said layer of non-wetting material is deposited near the rim of the crucible;   wherein the non-wetting material is deposited onto the crucible by one selected from the group consisting of RF magnetron sputtering, chemical vapor deposition, thermal spray, thermal evaporation, dip coating of precursors followed by thermal treatment, and spray coating of precursors followed by thermal treatment; and   wherein the crucible has an estimated non-wetting material film thickness of 500-1000 nm.   
     
     
         2 . The apparatus for containment of a molten substance using non-wetting materials of  claim 2   wherein the layer of non-wetting material is one selected from the group consisting of MgAl 2 O 4 , oxides, Al 2 O 3 , nitrides, AlN, BN, carbides, and SiC.   
     
     
         3 . An apparatus for containment of a molten substance using non-wetting materials comprising:
 a crucible;   a layer of a non-wetting material deposited onto the crucible;   wherein said layer of non-wetting material is deposited near the rim of the crucible; and   wherein the step of depositing the non-wetting material onto the crucible was via RF magnetron sputtering and wherein the RF magnetron sputtering was at an energy density of ˜9 W/cm 2  and a pressure of 1-10 mT and wherein the crucible was held at room temperature for an estimated non-wetting material film thickness of 500-1000 nm; and   wherein the non-wetting material stops a molten substance at an edge of the non-wetting material and wherein the molten substance will not advance further.   
     
     
         4 . The apparatus for containment of molten aluminum using non-wetting materials of  claim 3   wherein the non-wetting material is one selected from the group consisting of MgAl 2 O 4 , oxides, Al 2 O 3 , nitrides, AlN, BN, carbides, and SiC.   
     
     
         5 . The apparatus for containment of molten aluminum using non-wetting materials of  claim 4   wherein the non-wetting material has a surface energy that results in a contact angle of about 90° or greater when in contact with the molten substance.   
     
     
         6 . A containment-of-molten-aluminum crucible as a product of the process comprising the steps of:
 masking off a crucible using a mask to confine any deposition to the rim of the crucible;   depositing a non-wetting material onto the crucible; and   rotating the crucible during deposition;   wherein the step of depositing the non-wetting material onto the crucible was via RF magnetron sputtering and wherein the RF magnetron sputtering was at an energy density of ˜9 W/cm 2  and a pressure of 1-10 mT and wherein the crucible was held at room temperature for an estimated non-wetting material film thickness of 500-1000 nm.